Charging Contacts Manual €¦ · capacitor charging in the following equipment: automatic guided vehicles (AGVs), pallet shuttle systems, and material handling systems. Charging

Charging Contacts ManualXA-568705.1

www.conductix.us

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Charging ContactsManual

2 Charging Contacts Manual

CONDUCTIX INCORPORATEDThe technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS MANUAL. Conductix makes no warranty (and assumes no liability) as to function of equipment or operation of systems built according to customer design or of the ability of any of its products to interface, operate or function with any portions of customer systems not provided by Conductix.

Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered and reported to Seller within one year after shipment of such goods to Buyer.

Except where the nature of the defect is such that it is appropriate, in Seller’s judgment, to effect repairs on site, Seller’s obligation hereunder to remedy defects shall be limited to repairing or replacing (at Seller’s option) FOB point of original shipment by Seller, any part returned to Seller at the risk and cost of Buyer. Defective parts replaced by Seller shall become the property of Seller.

Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended by Seller and altered only as authorized by Seller. Seller is not responsible for defects which arise from improper installation, neglect, or improper use or from normal wear and tear.

Additionally, Seller’s obligation shall be limited by the manufacturer’s warranty (and is not further warranted by Seller) for all parts procured from others according to published data, specifications or performance information not designed by or for Seller.

Seller further agrees to replace or at Seller’s option to provide a refund of the sales price of any goods that do not conform to applicable specifications or which differ from that agreed to be supplied which non-conformity is discovered and forthwith reported to Seller within thirty (30) days after shipment to the Buyer. Seller’s obligation to replace or refund the purchase price for non-conforming goods shall arise once Buyer returns such goods FOB point of original shipment by Seller at the risk and cost of Buyer. Goods replaced by Seller shall become the property of Seller.

There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title and freedom from encumbrances and, except as herein expressly stated and particularly, and without limiting the foregoing, there is no guarantee or warranty, express or implied, of merchantability or of fitness for any particular purpose or against claim of infringement or the like.

Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyer’s design or of the ability of any goods to interface, operate or function with any portions of Buyer’s system not provided by Seller.

Seller’s liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of, connected with, or resulting from the manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in no case exceed the price paid for the product or services or any part thereof which give rise to the claim. In no event shall Seller be liable for consequential, special, incidental or other damages, nor shall Seller be liable in respect of personal injury or damage to property not the subject matter hereof unless attributable to gross misconduct of Seller, which shall mean an act or omission by Seller demonstrating reckless disregard of the foreseeable consequences thereof.

Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities and design functions or under abnormal conditions. Seller assumes no liability for loss of time, damage or injuries to property or persons resulting from the use of Seller’s products. Buyer shall hold Seller harmless from all liability, claims, suits and expenses in connection with loss or damage resulting from operation of products or utilization of services, respectively, of Seller and shall defend any suit or action which might arise there from in Buyer’s name - provided that Seller shall have the right to elect to defend any such suit or action for the account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.

Charging Contacts Manual 3

SECTION 1 - SAFETY 4Electrical Warnings 4Operational Warnings 4Maintenance Warnings 4Specifications and Listings 4Temperature, Voltage, and Ampere Ratings 4Product Markings 4

SECTION 2 - INSTALLATION 5Handling 5Application Types 5General Assembly Instructions 5Mounting 5Concrete Floor Mounting 7

SECTION 3 - MAINTENANCE 8System Inspections 8Brushes 8Brush Springs 8Electrical Connections 8

SECTION 4 - STORAGE 9Packaging 9Long-Term Storage 9

SECTION 5 - TROUBLESHOOTING 10

SECTION 6 - REPLACEMENT PARTS 11

TABLE OF CONTENTS


SECTION 1 - SAFETY

ATTENTION• Read this entire booklet prior to attempting any installation and/or maintenance of this product.

Electrical WarningsInstall the charging contact system in accordance with the National Eletric Code (NEC) or local codes and/or ordinances applicable in your region.

DANGER

• Hazard of electrical shock or burn. Always disconnect the power before attempting to perform any service function. Follow lock out/tag-out procedures as outlined in OSHA section 1910.147 where appropriate.

Do not use charging contacts with electrical loads greater than the rated current and voltage. Information regarding the current and voltage rating of each contact is recorded on the component type label. Further details can be found in the product catalog.

Operational WarningsMeans of final installation and integrations of this equipment is the responsibility of the OEM integrator.

Modification of this equipment may cause excessive wear or failure and will void the warranty.

Modification may cause safety and fire hazards, the end user takes sole responsibility for any modifications made to the product and in doing so absolves Conductix-Wampfler from any liability.

Maintenance WarningsExercise care while installing, servicing, adjusting, and operating the charging contacts and charging system.

Periodically check all fasteners and hardware to ensure they are properly tightened. Reference the drawing provided with the product for fastener torque specifications.

If you have any questions concerning the use or installation of your product, contact the factory:

• North & South America: +1 (800) 521-4888• Europe & Asia: +49 7621 6620

Specifications and ListingsThe charging contact products are built to comply with UL and IEC specifications and standards, but are not generally certified or listed by an independent body.

Some charging contact products may be CE listed, please consult the factory for additional details.

Temperature, Voltage, and Ampere RatingsThe charging contact products are rated to withstand a maximum operating temperature of 100°C (212°F) and minimum operating temperature of -20°C (-4°F).

The current and voltage rating of each contact is recorded on the component type label. Further details can be found in the product catalog.

Charging contacts can be supplied with a large variety of connections, voltage ratings, and ampere ratings. Consult the factory for additional details.

Product MarkingsEach base plate and vehicle collector is marked with a type label containing the Conductix name and logo, the product catalog number, and the voltage and ampere rating for the product.


SECTION 2 - INSTALLATIONHandlingNever support the unit by brush leads or connecting cables. Always carry the unit by supporting the plastic base plate or collector plate.

Application TypesCommon applications include, but are not limited to, battery or capacitor charging in the following equipment: automatic guided vehicles (AGVs), pallet shuttle systems, and material handling systems.

Charging contact assemblies can be purchased as a complete set, base and collector, or as individual components. See Figure 5-1 for additional details.

NOTE• Enclosures are not provided with charging contact

assemblies. The OEM integrator must provide an appropriate enclosure to meet applicable safety standards in their region.

General Assembly Instructions1. Torque all fasteners to the specified value(s) indicated on the

drawing provided with the product.

NOTE• Due to the large variety of possible mounting configurations,

fasteners for mounting the collector and base plate are not provided with the product. Reference the provided drawing for fastener clearance hole sizes.

Mounting1. Mount the collector assembly using the provided clearance

holes for socket head cap screws. See Figure 5-2.

2. The collector assembly should be supported around the clearance hole location, out to a minimum diameter of 2 times the clearance hole diameter. See Figure 5-3.

NOTE• Care must be taken to ensure the brush lead wires are not

damaged during the installation process, and have sufficient room to allow for movement of the brush pack. Brush pack movement is limited to the 5.5mm (0.22in). See Figure 5-2.

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Figure 5-1 Charging Contact Assembly Components, Collector, and Base Plate

1. Collector Assembly2. Base Plate Assembly

Maximum Movement0.22” (5.5mm)

Fixe

d Le

ngth

Figure 5-2 Allowable Brush Pack Movement

Ø2DMinimum Support Area

ØDClearance

Hole

Figure 5-3 Top of Collector Showing Mounting Hole and Minimum Support Area


SECTION 2 - INSTALLATION

NOTE• Provisions for making the electrical connections are

provided on the collector assemblies. Reference the provided drawing for brush lead lug size.

• Care must be taken when connecting the brush leads to ensure the correct phases are clustered together. Any fault condition resulting from improper installation is the responsibility of the user.

1. Mount the base plate assembly using the provided clearance holes for socket head cap screws. See Figure 6-1.

2. The base plate assembly should be supported around the clearance hole location, out to a minimum diameter of 2 times the clearance hole diameter, and along the outer 3.0mm (0.12in) minimum perimeter of the plate.

NOTE• Provisions for making the electrical connections are

provided on the bottom of the base plate assembly. • Care must be taken when connecting the cable

lugs to ensure the correct phases are clustered together. Reference the provided drawing for cable lug size. Any fault condition resulting from improper installation is the responsibility of the user.

3. The base plate must be mounted in a suitable enclosure for the service environment.

4. For 60Vdc (25Vac) service, per IEC 60664-1 (UL 840), pollution degree 3, a minimum clearance and creepage distance of 2.2mm (0.09in) must be maintained between each phase, and phase to ground. See Figure 6-2.

NOTE• This value may vary based on voltage, enclosure type,

and regional standards.

Figure 6-1 Bottom of Base Plate Showing Mounting Holes and Minimum Support Area.

0.12” (3mm)TYP

ØDClearance Hole

Ø2DMinimum Support Area

0.09” (2.2mm)Minimum Clearance

Figure 6-2 Bottom of Base Plate Showing Minimum Clearance


SECTION 2 - INSTALLATIONConcrete Floor MountingSome configurations may require a floor installation.

1. Install AGV-Collectors on vehicle in direction of travel.

2. Install AGV-Base Plate on top of the floor.

NOTE• Reference the supplied drawing to determine the

collector’s contact dimension.• Allowable Tolerance: +/- 2 mm.

3. Seal around the edge of the base plate using an RTV silicone or foam gasket material.

4. Set base plates on top of 1 concrete cutout square. See Figure 7-1.

NOTE• Concrete cutout size will vary on application.• The base concrete material must have a minimum

thickness of 3.0”.

5. Use a ruler or scale and permanent marker to draw the layout of the base plates and mounting holes on the concrete cutout square. See Figure 7-1.

6. Drill pilot holes for concrete anchors. Conductix-Wampfler recommends steel drop-in type anchors. See Figure 7-2.

7. Be sure to drill depth of anchor only and hammer with set tool when anchor is flush with top of concrete. Follow concrete anchor manufacturer’s instructions. See Figure 7-2.

8. Set steel drop-in anchors (requires a set tool). See Figure 7-2.

9. Place bolts in anchors but do not tighten down - this will prevent concrete dust and small pieces from falling in the holes.

10. Cut the concrete perimeter first and then make small cross cuts. To minimize chisel use, use a diamond concrete cutting wheel. See Figure 7-3.

11. Use diamond concrete cutting wheel and chisel to remove large pieces of concrete after cutting. See Figure 7-3.

12. Clean the surface of the concrete cutout square of any debris.

13. Install cables onto base plates.

NOTE• Concrete cuts may need to be extended to

accommodate cabling.

14. Remove bolts and set base plates on concrete cutout square layout.

15. Replace bolts and tighten to manufacturer’s torque specification.

16. If desired, fill the open cuts with an appropriate epoxy.

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Figure 7-1 1. Concrete Cutout2. Base Plates

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Figure 7-2 1. Mounting Holes

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3

Figure 7-3 Finished Product1. Diamond Concrete Cutting Wheel2. Chisel3. Hammer4. Brush


SECTION 3 - MAINTENANCE

ATTENTION• Before performing inspections and/or maintenance procedures, ensure all power is disconnected and all safety procedures are

followed.

System Inspections1. Perform the first inspection after the charging system has cycled 100 times.

2. Ensure that all electrical and mechanical connectors are properly secured, and that the mechanical alignment is within specification. Reference the provided drawing for additional alignment detail.

3. Perform period inspections every 15,000 – 20,000 charging cycles. During these inspections ensure that all electrical and mechanical connectors are properly secured.

Brushes1. Inspect the electrical brushes on the collector for wear. If the

distance from the bottom of the brush holder to the brush surface is less than 7.0mm (0.28in), replace the brush. See Figure 8-1.

2. Inspect the brush lead wires to ensure proper function and alignment with the clearance holes in the collector.

3. Inspect the contact surfaces on the base plate for wear.

4. Remove surface dirt, oxidation, pitting, and other contaminants from the contact surfaces via a brass brush or 320 grit sand paper.

ATTENTION• Do not use solvents or chemicals to clean the contact

surfaces and/or brushes.

Brush Springs1. Inspect and test the brush springs to ensure proper contact

pressure.

2. Measure the force required to depress the brush assembly, if contact force falls below the values shown in Table 8-1, replace the entire collector assembly.

Electrical Connections1. Inspect all electrical connections for corrosion.

2. Ensure that all fasteners are properly tightened.

NOTE• Poor electrical connections can lead to increased

electrical resistance and poor charging performance.

Brush Minimum Force (N/lbf)

20A 11 N / 2.5 lbf

50A 29 N / 6.5 lbf

75A 37 N / 8.4 lbf

Table 8-1 Minimum Brush Contact Force

0.28” (7.0mm)Minimum

Figure 8-1 Brush Height Measurement


SECTION 4 - STORAGEPackagingWhen storing charging contacts or sub assembly components care must be taken to ensure the brush contact face and contact plate are protected from dirt, debris, abrasion, oils, grease, and corrosion.

Plastic bags are recommended to protect the charging contacts or sub assembly components.

Long-Term StorageStore charging contacts or components in a dry environment to prevent the formation of corrosion or oxidation on the contact surfaces.

Before use, clean the brush and contact surfaces to remove dirt, oxidation, pitting, and other contaminants via a brass brush or 320 grit sand paper.


SECTION 5 - TROUBLESHOOTINGTroubleshootingPotential issues and solutions are shown below in Table 10-1, contact the factory for additional support.

Issue Potential Cause Solution

Intermittent charging or loss of charging current

Mechanical alignment

Inspect the contact sets mechanical alignment, reference the supplied drawing for further details

Electrical connections

Inspect the electrical connections to the base plate and contact brushes

Brush contact Inspect the brush pressure, brush, and contact plate

Damage to brush or contact plate

Mechanical alignment

Inspect the contact sets mechanical alignment, reference the supplied drawing for further details

Table 10-1 Troubleshooting Problems, Potential Cause, and Solution


SECTION 6 - REPLACEMENT PARTSReplacement PartsReplacement parts are shown below in Table 11-1 and Table 11-2, contact the factory for additional support or a quotation.

ATTENTION• Only mate base and collectors with matching base or

collector.

NOTE• The parts listed in Table 11-2 are not an all inclusive list. If

you do not see the part number you require in these tables please contact the factory.

Brush Ampere Rating Part Number

20A 562687

50A 562696

75A 562700

Table 11-1 Replacement Brushes

System Ampere Rating

Collector Part Number

Base Plate Part Number

20A BCC020A2WO BCB020A2WO









200A + 20A BCC200A2WP BCB200A2WP




Table 11-2 Replacement Collector and Base Plate Assemblies

Charging Contacts Manual XA-568705.1

Contact us for our Global Sales Offices

www.conductix.us

USA / LATIN AMERICA

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Omaha, NE 68127

Customer Support

Phone +1-800-521-4888

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Apodaca, NL México 66600

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Vila Progresso

Itu, São Paulo, Brasil

CEP: 13313-534

Customer Support

Phone (+55 11) 4813 7330

Fax (+55 11) 4813 7357

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Charging Contacts Manual €¦ · capacitor charging in the following equipment: automatic guided vehicles (AGVs), pallet shuttle systems, and material handling systems. Charging